Tissue cutting washer for right angle surgical stapler

ABSTRACT

A staple cartridge unit configured for use with a surgical stapler includes a cartridge housing having a deck and a plurality of openings that house staples configured to be driven distally into tissue positioned against the deck. A knife movably disposed within the cartridge housing is configured to be driven distally through the tissue. An anvil arranged distal to the cartridge housing includes an elongate slot and a plurality of staple-forming pockets. A cutting washer is fixed relative to the anvil and includes a cutting portion disposed within the elongate slot of the anvil. The knife is movable distally to cut tissue against the cutting portion. The cutting washer includes a pair of side flanges that extend transversely to the anvil and are configured to cover a gap defined between the anvil and a distal support structure of the surgical stapler in which the staple cartridge unit is received.

BACKGROUND

Some surgical staplers are operable to clamp down on one or more layers of patient tissue, form staples through the layers of tissue to substantially seal the layers of tissue together near the formed staples, and cut through the layers of clamped tissue for forming severed ends of operatively sealed tissue. An exemplary stapling instrument includes a pair of cooperating elongate jaw members, where each jaw member is adapted to be inserted into a patient and positioned relative to tissue that is to be stapled. One of the jaw members supports a staple cartridge having at least two laterally spaced rows of staples contained therein, and the other jaw member supports an anvil having staple-forming pockets configured to align with the rows of staples in the staple cartridge. Generally, the stapling instrument further includes one or more pusher bars that are actuatable relative to the jaw members to drive staples from the staple cartridge, through tissue clamped between the jaw members, and against the anvil for forming, and also to drive a knife member through the clamped tissue and thereby cut the tissue simultaneously with or subsequent to the stapling. In this manner, the stapling instrument is operable to form a plurality of laterally spaced rows of deformed staples in the clamped tissue, where such rows may comprise linear rows and/or arcuate rows. The knife blade may cut the tissue along a linear or arcuate path that extends between adjacent rows of the staples formed in the clamped tissue.

Merely exemplary surgical staplers are disclosed in U.S. Pat. No. 5,605,272, entitled “Trigger Mechanism for Surgical Instruments,” issued Feb. 25, 1997; U.S. Pat. No. 5,697,543, entitled “Linear Stapler with Improved Firing Stroke,” issued Dec. 16, 1997; U.S. Pat. No. 6,988,650, entitled “Retaining Pin Lever Advancement Mechanism for a Curved Cutter Stapler,” issued Jan. 24, 2006; U.S. Pat. No. 7,134,587, entitled “Knife Retraction Arm for a Curved Cutter Stapler,” issued Nov. 14, 2006; U.S. Pat. No. 7,147,139, entitled “Closure Plate Lockout for a Curved Cutter Stapler,” issued Dec. 12, 2006, U.S. Pat. No. 7,147,140, entitled “Cartridge Retainer for a Curved Cutter Stapler,” issued Dec. 12, 2006; U.S. Pat. No. 7,204,404, entitled “Slotted Pins Guiding Knife in a Curved Cutter Stapler,” issued Apr. 17, 2007; and U.S. Pat. No. 7,207,472, entitled “Cartridge with Locking Knife for a Curved Cutter Stapler,” issued Apr. 24, 2007; and U.S. Pat. No. 10,045,780, entitled “Method of Applying Staples in Lower Anterior Bowel Resection,” issued Aug. 14, 2018. The disclosure of each of the above-cited U.S. patents and U.S. patent publications is incorporated by reference herein.

While various kinds of surgical stapling instruments and associated components have been made and used, it is believed that no one prior to the inventor(s) has made or used the invention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.

FIG. 1A depicts a perspective view of an exemplary surgical stapler having a handle assembly, a shaft assembly, and an end effector, showing a tissue retaining pin actuation system in a retracted position and the end effector in an open state;

FIG. 1B depicts a perspective view of the surgical stapler of FIG. 1A, showing the tissue retaining pin actuation system in an extended position while the end effector remains in the open state;

FIG. 1C depicts a perspective view of the surgical stapler of FIG. 1A, showing the end effector in a closed state via actuation of a closure system, while the tissue retaining pin actuation system remains in the extended position;

FIG. 1D depicts a perspective view of the surgical stapler of FIG. 1A, showing the end effector in a fired state via actuation of a firing system to effect stapling and cutting of tissue captured by the end effector, while the tissue retaining pin actuation system remains in the extended position;

FIG. 2 depicts a partially disassembled perspective view of the surgical stapler of FIG. 1A;

FIG. 3 depicts a disassembled perspective view of actuatable components of the shaft assembly of the surgical stapler of FIG. 1A, including a closure bar of the closure system, a staple bar of the firing system, and a knife bar of the firing system;

FIG. 4A depicts a side elevational view of the handle assembly of the surgical stapler of FIG. 1A, with various components omitted for clarity, showing the tissue retaining pin actuation system in an extended position to retain tissue while the closure system and the firing system are in unactuated states;

FIG. 4B depicts a side elevational view of the handle assembly of the surgical stapler of FIG. 1A, with various components omitted for clarity, showing the closure system actuated via a closure trigger to close the end effector and thereby clamp tissue;

FIG. 4C depicts a side elevational view of the handle assembly of the surgical stapler of FIG. 1A, with various components omitted for clarity, showing the firing system actuated via a firing trigger to fire the end effector and thereby staple and cut tissue while the end effector remains in the closed state;

FIG. 5 depicts a perspective view of the surgical stapler of FIG. 1A, showing a staple cartridge unit of the end effector separated from a distal support structure of the end effector;

FIG. 6 depicts a distal left side perspective view of the staple cartridge unit of the surgical stapler of FIG. 1A;

FIG. 7 depicts a proximal right side perspective view of the staple cartridge unit of the surgical stapler of FIG. 1A;

FIG. 8 depicts a disassembled perspective view of the staple cartridge unit of the surgical stapler of FIG. 1A;

FIG. 9A depicts a side elevational view of the end effector of the surgical stapler of FIG. 1A, showing a lockout member of the end effector in a lockout position when a staple cartridge unit is absent from the distal support structure;

FIG. 9B depicts a side elevational view of the end effector of the surgical stapler of FIG. 1A, showing the lockout member in a bypass position when an unspent staple cartridge unit is seated within the distal support structure;

FIG. 10 depicts a side elevational view of a distal portion of the end effector of the surgical stapler of FIG. 1A following insertion of the staple cartridge unit into the distal support structure;

FIG. 11 depicts a sectional view of the distal portion of the end effector of the surgical stapler of FIG. 1A, showing interaction of a tissue cutting washer of the staple cartridge unit with the distal support structure;

FIG. 12A depicts a side sectional view of the end effector of the surgical stapler of FIG. 1A, showing a tissue retaining pin in a retracted position while the end effector is in an open state;

FIG. 12B depicts a side sectional view of the end effector of the surgical stapler of FIG. 1A, showing the tissue retaining pin in an extended position to retain tissue while the end effector remains in the open state;

FIG. 12C depicts a side sectional view of the end effector of the surgical stapler of FIG. 1A, showing the end effector actuated to a closed state to clamp tissue while the tissue retaining pin remains in the extended position;

FIG. 12D depicts a side sectional view of the end effector of the surgical stapler of FIG. 1A, showing the end effector further actuated to a fired state to staple and cut tissue while remaining in the closed state;

FIG. 13 depicts a side elevational view of another exemplary tissue cutting washer coupled with the distal support structure of the end effector of the surgical stapler of FIG. 1A;

FIG. 14 depicts a side elevational view of another exemplary tissue cutting washer coupled with the distal support structure of the end effector of the surgical stapler of FIG. 1A;

FIG. 15 depicts a perspective view of another exemplary tissue cutting washer coupled with the distal support structure of the end effector of the surgical stapler of FIG. 1A;

FIG. 16 depicts a perspective sectional view of another exemplary tissue cutting washer coupled with the distal support structure of the end effector of the surgical stapler of FIG. 1A;

FIG. 17 depicts a perspective view of another exemplary tissue cutting washer suitable for use with the surgical stapler of FIG. 1A, shown in combination with another exemplary anvil;

FIG. 18 depicts an enlarged perspective view of a cutting portion of another exemplary tissue cutting washer suitable for use with the surgical stapler of FIG. 1A, shown in combination with an exemplary anvil;

FIG. 19 depicts a perspective view of a portion of another exemplary tissue cutting washer suitable for use with the surgical stapler of FIG. 1A, shown in combination with an exemplary anvil;

FIG. 20 depicts a perspective view of an exemplary staple cartridge housing configured for use with the surgical stapler of FIG. 1A;

FIG. 21A depicts an enlarged side sectional view of the staple cartridge unit of the surgical stapler of FIG. 1A having an alternatively configured tissue cutting washer, showing the staple cartridge unit in an open state; and

FIG. 21B depicts an enlarged side sectional view of the staple cartridge unit of FIG. 21A, showing the staple cartridge unit in a closed state for clamping tissue.

The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

For clarity of disclosure, the terms “proximal” and “distal” are defined herein relative to a surgeon, or other operator, grasping a surgical instrument having a distal surgical end effector. The term “proximal” refers to the position of an element arranged closer to the surgeon, and the term “distal” refers to the position of an element arranged closer to the surgical end effector of the surgical instrument and further away from the surgeon. Moreover, to the extent that spatial terms such as “top,” “bottom,” “upper,” “lower,” “vertical,” “horizontal,” “left,” “right” or the like are used herein with reference to the drawings, it will be appreciated that such terms are used for exemplary description purposes only and are not intended to be limiting or absolute. In that regard, it will be understood that surgical instruments such as those disclosed herein may be used in a variety of orientations and positions not limited to those shown and described herein.

As used herein, the terms “about,” “approximately,” and the like in connection with any numerical values or ranges of values are intended to encompass the exact value(s) referenced, as well as a suitable dimensional tolerance that enables the referenced feature or combination of features to function for the intended purpose described herein.

I. Overview of Exemplary Right Angle Surgical Stapler

FIG. 1A depicts an exemplary right angle linear surgical stapler (10) that is configured to staple and cut tissue in various non-endoscopic (“open”) surgical procedures, including colorectal, thoracic, and bariatric procedures, for example. Right angle linear surgical stapler (10) (also referred to as a “right angle linear cutter”) generally includes a handle assembly (12), a shaft assembly (14) extending distally from handle assembly (12), and an end effector (16) at a distal end of shaft assembly (14). As described below, end effector (16) is provided with a “right angle” configuration such that end effector (16) clamps, staples, and cuts tissue in a plane that extends transversely at a right angle to a longitudinal axis defined by shaft assembly (14).

As described in greater detail below, surgical stapler (10) includes several actuation systems for operating end effector (16) via handle assembly (12) during a surgical procedure on a patient. In particular, surgical stapler (10) includes a tissue retaining pin actuation system (20) operable to initially retain tissue within end effector (16); a closure system (22) operable to clamp tissue with end effector (16); and a firing system (24) operable to subsequently staple and cut tissue with end effector (16).

While the teachings herein are shown and described in the context of a “linear” surgical stapler (10) configured to apply linear rows of staples and a linear cut line in tissue, it will be appreciated that any one or more of the teachings herein may be applied to a surgical stapler configured to apply staple rows and a tissue cut line with a non-linear (e.g., curved) configuration, such as a surgical stapler of the type disclosed in any one or more of the references incorporated by reference herein.

A. Handle Assembly and Shaft Assembly of Surgical Stapler

As shown in FIG. 1A, handle assembly (12) includes a housing (30) that defines a pistol grip (32), a saddle shaped slide (34) slidably disposed on an upper portion of handle housing (30), a pivotable closure trigger (36), and a pivotable firing trigger (38). Closure trigger (36) and firing trigger (38) are operatively coupled with end effector (16) via shaft assembly (14) such that end effector (16) is configured to close and thereby clamp tissue in response to actuation of closure trigger (36), and subsequently staple and cut tissue (i.e., “fire”) in response to actuation of firing trigger (38). FIG. 1A shows slide (34) and closure trigger (36) in unactuated configurations such that end effector (16) is configured to receive tissue laterally within a gap (G) (or “aperture”) defined between a cartridge housing (162) and an anvil (210) of a replaceable staple cartridge unit (160) (or “reload”) mounted within end effector (16). As shown in FIG. 1B, translating slide (34) distally toward end effector (16) extends a tissue retaining pin (176) of staple cartridge unit (160) distally for capturing the tissue between anvil (210) and cartridge housing (162). As shown in FIG. 1C, subsequently actuating closure trigger (36) toward pistol grip (32) drives cartridge housing (162) distally toward anvil (210), thereby clamping tissue therebetween. As shown in FIG. 1D, subsequently actuating firing trigger (38) toward pistol grip (32) drives staples distally into the clamped tissue and also cuts the tissue between formed staple lines with a knife member (194) (see FIG. 8), as described in greater detail below.

As shown in FIG. 2, surgical stapler (10) includes a pair of longitudinally extending side plates (40) that cooperate to define a frame structure of stapler (10) that supports tissue retaining pin actuation system (20), closure system (22), and firing system (24). Each side plate (40) includes a proximal frame portion (42) housed within handle housing (30); a medial shaft portion (44) that defines a respective outer lateral side of shaft assembly (14); and a distal jaw portion (46) having an upwardly extending distal hook (47). Distal jaw portions (46) cooperate with the distal end of a closure bar (50), described below, to define a U-shaped distal support structure (48) of end effector (16) that removably receives staple cartridge unit (160). As used herein, the term “U-shaped” refers to the shape presented by end effector (16) in any of the side elevational views depicted herein.

As shown in FIG. 3, slidably disposed between and supported by side plates (40) are elongate actuatable components of actuation systems (20, 22, 24), which operatively couple handle assembly (12) with staple cartridge unit (160); including a closure bar (50), a staple bar (60), and a knife bar (70). Closure bar (50) includes a cartridge-receiving distal portion (52) configured to receive and support staple cartridge unit (160). Closure bar (50) and staple bar (60) are each configured as a double-sided structure having first and second lateral sides spaced apart from one another, and an inner channel extending longitudinally therebetween. This configuration enables an arrangement of shaft assembly (14) in which knife bar (70) is nested and slidably disposed within the longitudinal inner channel of staple bar (60), and in which staple bar (60) in turn is nested and slidably disposed within the longitudinal inner channel of closure bar (50). Moreover, staple bar (60) and knife bar (70) are longitudinally translatable independently of closure bar (50) through a range of longitudinal motion that enables independent closure and firing of end effector (16). As described in greater detail below, closure bar (50) is operable to actuate cartridge housing (162) longitudinally relative to anvil (210) for clamping tissue in response to actuation of closure trigger (36). Staple bar (60) is operable to actuate a staple driver member (186) (see FIG. 8) longitudinally relative to cartridge housing (162) for stapling the clamped tissue. Knife bar (70) is operable to actuate knife member (194) (see FIG. 8) longitudinally relative to cartridge housing (162) and staple driver member (186) for cutting the clamped tissue.

Tissue retaining pin actuation system (20) of surgical stapler (10) includes slide (34) of handle assembly (12), tissue retaining pin (176) of staple cartridge unit (160), an elongate pushrod (80) extending longitudinally along an upper side of shaft assembly (14), and a pushrod driver (82) slidably disposed within handle assembly (12). A distal end of pushrod (80) is configured to releasably couple with tissue retaining pin (176) upon insertion of staple cartridge unit (160) into distal support structure (48) of end effector (16). A proximal end of pushrod (80) is coupled with pushrod driver (82), which in turn is coupled with slide (34). Accordingly, longitudinal translation of slide (34) between proximal and distal positions drives longitudinal translation of tissue retaining pin (176) relative to cartridge housing (162) between retracted and extended positions. As shown in FIG. 1A, tissue retaining pin (176) is configured to assume a retracted position in which retaining pin (176) is housed within cartridge housing (162) when slide (34) is in a proximal position. As shown in FIG. 1B, tissue retaining pin (176) is configured to assume an extended position in which a distal end of retaining pin (176) engages anvil (210), thereby retaining tissue positioned within gap (G) of staple cartridge unit (160), when slide (34) is advanced to the distal position.

Closure system (22) of surgical stapler (10) includes closure trigger (36) of handle assembly (12) and closure bar (50). As shown in FIGS. 2 and 4A-4C, closure trigger (36) is pivotably coupled with handle housing (30) about a pair of laterally extending posts (90). An upper arm (92) of closure trigger (36) having a vertically slotted distal portion is operatively coupled with a proximal end of closure bar (50) by a pair of closure links (96). A proximal end of each closure link (96) is pivotably coupled with a laterally extending post (93) of closure trigger upper arm (92). A distal end of each closure link (96) is pivotably coupled with the proximal end of closure bar (50) about a laterally extending post (54) of closure bar (50).

As shown in FIGS. 4A-4B, pivoting of closure trigger (36) toward pistol grip (32) pivots advances closure trigger upper arm (92) distally and downwardly, thereby driving closure bar (50) distally via closure links (96). In turn, cartridge-receiving distal portion (52) of closure bar (50) drives cartridge housing (162) distally toward anvil (210). In this manner, end effector (16) is actuated from an open state (FIGS. 1A-1B) in which tissue is positionable within end effector (16), to a closed state (FIG. 1C) in which the tissue is clamped between cartridge housing (162) and anvil (210). A closure return spring (98) housed within pistol grip (32) of handle assembly (12) resiliently biases closure trigger (36) toward the unactuated state, and thus end effector (16) toward the open state.

In the present version, closure bar (50) is further configured to cooperate with tissue retaining pin actuation system (20) to automatically actuate retaining pin (176) distally to its extended position when an operator squeezes closure trigger (36). In that regard, as shown best in FIGS. 4A-4B, handle assembly (12) further includes a pair of camming yokes (100) rotatably disposed along the outer sides of closure links (96). Each camming yoke (100) includes an angled slot (102) that slidably receives a respective proximal post (54) of closure bar (50). As closure trigger (36) is actuated toward pistol grip (32), proximal posts (54) rotatably drive camming yokes (100) distally such that cam lobes (104) of yokes (100) engage corresponding side posts (84) of pushrod driver (82), thereby actuating pushrod (80) and thus tissue retaining pin (176) distally. Such automatic extension of tissue retaining pin (176) during closure of end effector (16) may be useful in the event that the operator does not manually actuate retaining pin (176) distally via slide (34) prior to actuating closure trigger (36).

Closure system (22) of the present example is further configured to releasably lock closure trigger (36) in the actuated position to provide effective clamping of tissue with end effector (16) without having to continuously squeeze closure trigger (36). As shown best in FIGS. 4A-4B, a release button (110) is pivotably disposed at a proximal end of handle assembly (12). A locking pawl (112) extends distally from an upper end of release button (110) and includes a pawl lug (114) that is resiliently biased into contact with an upper end of closure trigger upper arm (92), via a release button spring (116). Accordingly, pawl lug (114) is configured to slide along an upper surface of closure trigger upper arm (92) as closure trigger (36) is squeezed toward pistol grip (32). As shown in FIG. 4B, upon closure trigger (36) reaching a fully actuated position, pawl lug (114) drops into a proximal upper notch (94) of closure trigger upper arm (92), thereby locking closure trigger (36) in the fully actuated position. Should the operator wish to then reopen end effector (16), for example to reposition tissue within end effector (16) or otherwise release tissue once firing is complete, the operator may depress release button (110) to disengage pawl lug (114) from closure trigger (36). Via the resilient bias provided by closure return spring (98), closure trigger (36) then returns to the unactuated state and end effector (16) returns to the open state, shown in FIGS. 1A and 4A.

Firing system (24) of surgical stapler (10) includes firing trigger (38) of handle assembly (12), staple bar (60), knife bar (70), and staple driver member (186) and knife member (194) of staple cartridge unit (160). Features of knife bar (70) and staple driver member (186) are described in greater detail below in connection with FIG. 8. As shown in FIGS. 2 and 4A, firing trigger (38) of the present example is configured as an assembly having a lower shroud (120) that extends downwardly from handle housing (30) and is engageable by an operator; a pair of plates having arcuate upper arms (122) that extend upwardly and distally from lower shroud (120) and are positioned with handle housing (30); a rotatable cam pin (124) extending laterally between the free distal upper ends of arcuate upper arms (122); and a firing lockout projection (126) extending distally from the lower ends of arcuate upper arms (122) within handle housing (30). Cam pin (124) may be configured and operable in accordance with any of the teachings of U.S. Pat. App. No. [Atty. Ref. END9088USNP1], entitled “Cartridge Based Lockout Mechanism for Right Angle Surgical Stapler,” filed on even date herewith, the disclosure of which is incorporated by reference herein.

Firing trigger (38) is pivotably coupled with handle housing (30) via a laterally extending pivot pin (128). Additionally, firing trigger (38) is positioned distal to closure trigger (36) such that arcuate upper arms (122) of firing trigger (38) are received into the slotted distal portion of closure trigger upper arm (92) as closure trigger (36) is actuated toward pistol grip (32). As shown in FIGS. 4A-4B, as the operator squeezes closure trigger (36) fully toward pistol grip (32), distally facing ledges (95) disposed within the distal slotted portion of closure trigger upper arm (92) engage cam pin (124) of firing trigger (38) and drive cam pin (124) distally by an initial amount. This causes the lower end of firing trigger (38) to pivot partially toward pistol grip (32) simultaneously with closure trigger (36), as shown in FIG. 4B.

As shown in FIG. 4C, once end effector (16) has reached the fully closed state, further actuation of firing trigger (38) toward pistol grip (32) operates to “fire” end effector (16). In particular, outer portions of cam pin (124) engage proximal edges (62) of staple bar (60), thus driving staple bar (60) distally relative to closure bar (50). As described in greater detail below in connection with FIGS. 12A-12D, distal edges (64) of staple bar (60) engage a proximal end of staple driver member (186) within staple cartridge housing (162), thus driving staple driver member (186) distally through staple cartridge housing (162) to drive staples into tissue clamped by end effector (16). Actuation of firing trigger (38) toward its fully actuated state also causes a medial portion of cam pin (124), disposed between arcuate upper arms (122) of firing trigger (38), to engage a rounded proximal edge (72) of knife bar (70), thus driving knife bar (70) distally relative to closure bar (50). As described in greater detail below in connection with FIGS. 12A-12D, a distal edge (74) of knife bar (70) engages a proximal end of knife member (194) within staple cartridge housing (162), thus driving knife member (194) distally through staple driver member (186) to cut the tissue clamped by end effector (16).

Firing system (24) of the present example is suitably configured such that staple bar (60) and knife bar (70) translate distally together as firing trigger (38) is actuated through a primary range of motion toward pistol grip (32); and such that knife bar (70) continues to translate distally relative to staple bar (60) as firing trigger (38) is further actuated through a final range of motion toward pistol grip (32). Advantageously, such a configuration ensures that the tissue clamped by end effector (16) is fully stapled and that proper hemostasis is thus achieved along the intended tissue cut line before the tissue is cut by knife member (194).

As shown in FIG. 2, firing system (24) further includes a knife return spring (130) housed within handle assembly (12). Knife return spring (130) is anchored at its distal end to the distal end of knife bar (70), and at its proximal end to the distal end of closure bar (50). Accordingly, knife return spring (130) is operable to resiliently bias knife bar (70) proximally relative to closure bar (50) and staple bar (60) when firing trigger (38) is released. As shown in FIGS. 3 and 12A-12D, knife bar (70) includes a distal hook (76) that is captured by knife member (194) to thereby secure knife member (194) axially to knife bar (70). Accordingly, when the operator releases firing trigger (38) after completing a firing stroke, knife bar (70) and knife member (194) automatically retract proximally to safely house a distal cutting edge (200) of knife member (194) within staple cartridge housing (162).

As shown in FIG. 2, surgical stapler (10) of the present example further includes a proximal firing lockout mechanism in the form of a pivotable lever (140), which is operable to inhibit actuation of firing trigger (38) until end effector (16) has been fully closed by closure trigger (36). Firing lockout lever (140) is housed within handle assembly (12) and is pivotably mounted to an outer side of the proximal frame portion (42) of the left side plate (40). Firing lockout lever (140) is resiliently biased by a spring (146) toward a position in which a lower tab (142) of proximal lockout lever (140) blocks downward movement of firing lockout projection (126) of firing trigger (38), thus inhibiting actuation of firing trigger (38) when closure trigger (36) has not been fully actuated to close end effector (16). When closure trigger (36) reaches a fully actuated state, an upper arm (144) of firing lockout lever (140) is driven downwardly by pawl lug (114) of release button (110), thus rotating lower tab (142) away from firing lockout projection (126) and permitting actuation of firing trigger (38). Firing lockout lever (140) and exemplary variations thereof are described in greater detail below. Firing lockout lever (140) and other lockout features of surgical stapler (10) may be further configured and operable in accordance with any of the teachings of U.S. Pat. App. No. [Atty. Ref. END9087USNP1], entitled “Clamping Based Lockout Mechanism for Right Angle Surgical Stapler,” filed on even date herewith, the disclosure of which is incorporated by reference herein.

Though not shown, shaft assembly (14) of surgical stapler (10) may include various additional components, such as an articulating joint, or may include a rearrangement of various components such that shaft assembly (14) may be modular relative to handle assembly (12).

B. End Effector of Surgical Stapler

End effector (16) of surgical stapler (10) includes distal support structure (48) defined by distal portions of side plates (40), cartridge-receiving distal portion (52) of closure bar (50), distal portions of staple bar (60) and knife bar (70), and replaceable staple cartridge unit (160). As shown best in FIGS. 5-8, staple cartridge unit (160) of the present version includes cartridge housing (162) and anvil (210) spaced apart from one another so as to define an axial gap (G) therebetween for receiving patient tissue to be stapled and cut. Cartridge housing (162) includes a distally facing deck (164) that is configured to clamp tissue against anvil (210) and extends transversely to a longitudinal axis of shaft assembly (14), along with anvil (210), thus providing end effector (16) with a “right angle” configuration.

Cartridge deck (164) includes an elongate linear knife slot (166) configured to slidably receive a knife (198) therethrough, and a plurality of staple openings (168) arranged in linear rows along either side of elongate linear knife slot (166) and configured to house a plurality of unformed staples (170) therein. Deck (164) of the present example further includes a plurality of stand-off features (172) interposed with staple openings (168) and configured to optimize grip and compression of patient tissue as the tissue is clamped between deck (164) and anvil (210). Deck (164) may be further configured in accordance with at least some of the teachings of U.S. patent application Ser. No. 16/234,740, entitled “Surgical Stapler with Sloped Staple Deck for Varying Tissue Compression,” filed Jan. 14, 2019, the disclosure of which is incorporated by reference herein.

An elongate upper body portion (174) of cartridge housing (162) slidably houses tissue retaining pin (176) and a couplet (180) secured to a proximal end of tissue retaining pin (176). Couplet (180) is configured to releasably couple tissue retaining pin (176) with a distal end of pushrod (80) of tissue retaining pin actuation system (20) when staple cartridge unit (160) is seated within distal support structure (48) of end effector (16). An end cap member (182) secured to a proximal end of upper body portion (174) is configured to constrain tissue retaining pin (176) and couplet (180) proximally within cartridge housing (162), while permitting tissue retaining pin (176) to translate between its proximal retracted position (see FIGS. 1A and 12A), and its distal extended position (see FIGS. 1B and 12B). Tissue retaining pin (176) includes a tapered distal tip (178) that is configured to pierce tissue as retaining pin (176) is extended toward anvil (210).

A lower body portion (184) of cartridge housing (162) slidably receives staple driver member (186) and knife member (194) therein. As shown best in FIG. 8, staple driver member (186) of the present version includes a base portion (188), a plurality of staple driver elements (190) projecting distally from base portion (188), and an interior channel (192) that extends axially through staple driver member (186) and is configured to slidably receive knife member (194). Each staple driver element (190) is configured to be slidably received within a respective staple opening (168) of cartridge housing (162) and drive a respective staple (170) from the opening (168) in response to actuation of closure trigger (36). While staple driver elements (190) of the present version are securely affixed to base portion (188), it will be appreciated that base portion (188) and staple driver elements (190) may be provided separately in other versions.

Knife member (194) includes a base portion (196) and a knife (198) secured to and extending distally from base portion (196) and having a distal cutting edge (200). Knife (198) is formed with a flat, plate-like shape that enables knife (198) to perform linear cuts on patient tissue. Knife member (194) is slidably received within interior channel (192) of staple driver member (186) such that knife (198) is configured to translate longitudinally through staple driver member (186) and elongate linear knife slot (166) of cartridge housing (162) for cutting tissue clamped by end effector (16) in response to full actuation of firing trigger (38).

As shown best in FIG. 8, anvil (210) of staple cartridge unit (160) includes a distal plate portion (212) and a coupling arm (214) extending proximally from a lower end of distal plate portion (212). Distal plate portion (212) is configured to cooperate with cartridge deck (164) to clamp tissue to be stapled and cut. Distal plate portion (212) includes an elongate linear slot (216) and a plurality of staple-forming pockets (218) arranged in linear rows along each side of slot (216). Pockets (218) are configured to receive and deform legs of staples (170) ejected from cartridge housing (162) for forming the staples (170) in tissue clamped between distal plate portion (212) and cartridge deck (164).

A guide pin (230) extends longitudinally between anvil plate portion (212) and cartridge housing (162) and is configured to guide longitudinal translation of cartridge housing (162) between the proximal open position (see FIGS. 1A and 12A) and the distal closed position (see FIGS. 1C and 12C). A proximal end of guide pin (230) is constrained by a proximal tab (220) of anvil coupling arm (214), shown in FIG. 8, and a distal end of guide pin (230) is constrained within a lower opening (222) formed in anvil plate portion (212). An upper opening (224) formed in anvil plate portion (212) is configured to receive and constrain tapered distal tip (178) of tissue retaining pin (176) in the extended position, such that tissue retaining pin (176) may cooperate with guide pin (230) to guide longitudinal translation of cartridge housing (162) relative to anvil (210). As seen in FIGS. 6-8, an inner side of guide pin (230) may include a longitudinal groove (232), which is configured to cooperate with a similar groove (234) (see FIGS. 12A-12D) to slidably guide knife (198) between retracted and extended positions relative to cartridge housing (162).

Staple cartridge unit (160) further includes a tissue cutting washer (240) fixed to anvil (210), and which is configured to cooperate with knife (198) to cut tissue clamped by end effector (16). As shown best in FIGS. 8 and 10-11, tissue cutting washer (240) includes an elongate, plate-like body (242) that extends along the distal side of anvil plate portion (212). Washer body (242) includes an elongate cutting element (244) that protrudes proximally through elongate slot (216) of anvil plate portion (212). Cutting element (244) functions as a cutting board by providing knife cutting edge (200) with a flat surface against which cutting edge (200) cuts tissue. At least cutting element (244) of tissue cutting washer (240) may comprise a polymeric material, such as high-density polyethylene (HDPE). In that regard, knife (198) may cut axially into cutting element (244), along its longitudinal centerline, when cutting tissue. While cutting element (244) of the present version provides a generally planar cutting surface, it will be appreciated that cutting element (244) may be alternatively configured in other versions, for example as described below in connection with FIGS. 16-19.

Tissue cutting washer (240) further includes a rounded tip (246) at an upper end of washer body (242), and a coupling arm (248) extending proximally from a lower end of washer body (242). Washer tip (246) captures and thereby constrains an upper end of anvil plate portion (212), and its rounded configuration promotes atraumatic interaction with patient tissue. A press-fit pin (250) is configured to be inserted through openings formed in proximal coupling arms (214, 248) of anvil (210) and tissue cutting washer (240), thereby securely coupling anvil (210) and cutting washer (240) together.

Tissue cutting washer (240) further includes a pair of side flanges (252) that extend along a full length of anvil plate portion (212). As shown in FIGS. 10 and 11, each side flange (252) extends proximally to cover a respective side edge of anvil plate portion (212), and distally to cover at least a portion of distal hook (47) of the respective side plate (40) defining distal support structure (48). Accordingly, and advantageously, side flanges (252) function to cover an axial gap (254) that may form between anvil plate portion (212) and distal hooks (47), thereby preventing tissue from entering into and getting pinched within axial gap (254) in a manner that might otherwise result in undesirable trauma to the tissue. As shown in FIG. 10, distal hooks (47) of stapler side plates (40) of the present version are swept proximally to accommodate slight distal deflection of distal hooks (47) during closure of end effector (16). As a result, axial gap (254) enlarges in a downward direction toward the transverse junction between anvil plate portion (212) and anvil coupling arm (214). As also shown in FIG. 10, side flanges (252) extend distally and downwardly relative to anvil plate portion (212) so as to completely cover axial gap (254) on both sides of end effector (16), thereby effectively preventing tissue from being trapped and pinched within axial gap (254) during closure of end effector (16). As shown in FIG. 11, the outer surfaces of side flanges (252) may be rounded to further enhance the atraumatic characteristics of the outer periphery of tissue cutting washer (240).

C. Exemplary Loading of Staple Cartridge Unit into Distal Support Structure of End Effector

FIGS. 9A and 9B show loading of staple cartridge unit (160) in its unused (or “unspent”) state into distal support structure (48) of end effector (16). As shown in FIG. 9A, and as described briefly above, distal support structure (48) is configured with a U-shaped side profile having a distal side defined by distal hooks (47), a proximal side defined by a proximal portion of distal jaw portion (46) and a distal end of cartridge-receiving distal portion (52) of closure bar (50), and an upwardly opening axial gap disposed therebetween.

Staple cartridge unit (160) is shown in FIGS. 9A-9B provided with a staple retainer (260) that is removably positioned between deck (164) and anvil plate portion (212) to retain staples (170) within staple openings (168), and to ensure proper axial spacing between deck (164) and anvil plate portion (212) as staple cartridge unit (160) is inserted into distal support structure (48). Staple retainer (260) may be configured and operable in accordance with at least some of the teachings of U.S. Pat. App. No. [Atty. Ref. END9090USNP1], entitled “Staple Retainer for Right Angle Surgical Stapler,” filed on even date herewith, the disclosure of which is incorporated by reference herein. Upon removal of staple retainer (260), staple cartridge unit (160) presents a U-shaped side profile similar to that of distal support structure (48), with a distal side defined by anvil plate portion (212) and tissue cutting washer (240), a proximal side defined by cartridge deck (164), and upwardly opening axial gap (G) disposed therebetween.

As shown in FIG. 9A, the user first aligns proximal side rails (202) formed on lower body portion (184) of cartridge housing (162) with inner channels (56) formed in cartridge-receiving distal portion (52) of closure bar (50) (see FIG. 3). As shown in FIG. 9B, the user then presses staple cartridge unit (160) downwardly into distal support structure (48) of end effector (16) such that proximal side rails (202) of cartridge housing (162) slide downwardly into inner channels (56) of closure bar (50), and such that distal hooks (47) of side plates (40) slide into grooves formed in the distal side of tissue cutting washer body (242) (see FIG. 11). As staple cartridge unit (160) fully seats within distal support structure (48), detent protrusions (204) formed on lower body portion (184) of cartridge housing (162) are receiving within respective openings (58) formed in cartridge-receiving distal portion (52) of closure bar (50), thereby removably securing staple cartridge unit (160) within distal support structure (48). Engagement of cartridge detent protrusions (204) with openings (58) may provide the user with tactile and/or audible feedback to confirm that staple cartridge unit (160) has been fully seated within distal support structure (48).

As shown in FIG. 9A, a distal lockout lever (270) is pivotably coupled to a distal end of staple bar (60). Distal lockout lever (270) extends distally toward distal edges (64) of staple bar (60) and knife bar (70) and is configured to releasably engage a fixed distal pin (280) that extends laterally through distal portions of side plates (40), closure bar (50), staple bar (60), and knife bar (70). Distal lockout lever (270) is resiliently biased toward a raised position shown in FIG. 9A and is pivotable toward a lowered position shown in FIG. 9B in response to engagement by a proximal end of staple driver member (186) upon insertion of an unspent staple cartridge unit (160) into distal support structure (48). In the raised position, distal lockout lever (270) lockingly engages fixed distal pin (280) and thereby inhibits distal actuation of staple bar (60) and knife bar (70), and thus firing of staple cartridge unit (160). In the lowered position, distal lockout lever (270) disengages fixed distal pin (280) and thus permits distal actuation of staple bar (60) and knife bar (70) for firing of staple cartridge unit (160). Distal lockout lever (270) and other lockout features of surgical stapler (10) may be further configured and operable in accordance with any of the teachings of U.S. Pat. App. No. [Atty. Ref. END9088USNP1], entitled “Cartridge Based Lockout Mechanism for Right Angle Surgical Stapler,” incorporated by reference above.

D. Exemplary Actuation of Surgical Stapler

Having described various structural features of surgical stapler (10) above, including staple cartridge unit (160), exemplary actuation of surgical stapler (10) during a surgical procedure will now be described below. After loading an unspent staple cartridge unit (160) into distal support structure (48) in the manner described above, end effector (16) is then suitably manipulated within a body cavity of a patient to position patient tissue within staple cartridge gap (G), between anvil plate portion (212) and cartridge deck (164). As shown in FIGS. 12A and 12B, pushrod (80) is then actuated distally via slide (34) to drive pushrod (80) distally, thereby extending tissue retaining pin (176) from cartridge housing (162) so that its distal tip (178) pierces through any tissue overlying the upper end of cartridge deck (164) and seats within the upper end of anvil plate portion (212). In this manner, the patient tissue is securely retained within cartridge gap (G) before closure.

As shown in FIG. 12C, closure bar (50) is then actuated distally via closure trigger (36), thereby driving cartridge housing (162) distally along guide pin (230) and tissue retaining pin (176) to clamp tissue between cartridge deck (164) and anvil plate portion (212). As shown in the present example, staple bar (60) and knife bar (70) actuate distally with closure bar (50) and cartridge housing (162) so that staple driver member (186) and knife member (194) are suitably positioned for firing upon full closure of end effector (16). As described above, end effector (16) is releasably maintained in the fully closed state by locking pawl (112) of release button (110) of handle assembly (12).

As shown in FIG. 12D, staple bar (60) and knife bar (70) are then actuated distally via firing trigger (38), thereby driving staple driver member (186) and knife bar (70) distally through cartridge housing (162). Staple driver elements (190) of staple driver member (186) advance distally through staple openings (168), thereby driving staples (170) housed therein distally through the clamped tissue and into staple-forming pockets (218) of anvil plate portion (212), such that the staples (170) are formed in the tissue. Knife member (194) drives knife (198) distally through elongate knife slot (166) of cartridge deck (164), through the clamped tissue, and against cutting element (244) of tissue cutting washer (240), thereby severing the clamped tissue along a linear cut line between the innermost rows of formed staples (170). Upon cutting fully through the clamped tissue, knife cutting edge (200) may penetrate distally into cutting element (244) of tissue cutting washer (240). Optionally, in response to such penetration, tissue cutting washer body (242) may fracture along knife cutting edge (200), thereby providing an audible indication (e.g., via a “snapping” sound) to the surgeon that the firing stroke is complete and that the clamped tissue has been fully stapled and severed.

As described above, and as shown in FIG. 12D, staple driver member (186) and knife member (194) may translate distally together through staple cartridge housing (162) as firing trigger (38) is actuated through a primary range of motion that results in stapling of the tissue. As shown in FIG. 12D, knife member (194) may then continue translating distally relative to a stationary staple driver member (186) as firing trigger (38) is further actuated through a final range of motion that results in cutting of the stapled tissue with knife (198). In this manner, the tissue clamped by end effector (16) is fully stapled before being severed.

As shown best in FIG. 7, a first lateral side of lower body portion (184) of cartridge housing (162) includes a detent arm (185) having a plurality of axially spaced recesses. Additionally, a first lateral side of base portion (188) of staple driver member (186) includes a laterally extending detent post (189), which is configured to detent axially along detent arm (206) as staple driver member (186) is driven distally through cartridge housing (162) when stapling clamped tissue. As shown best in FIG. 8, a second lateral side of base portion (188) of staple driver member (186) includes a detent arm (191) having a plurality of axially spaced recesses. Additionally, a second lateral side of base portion (196) of knife member (194) includes a laterally extending detent post (197), which is configured to detent axially along detent arm (191) as knife member (194) is driven distally through staple driver member (186) when cutting clamped tissue. Such detent features may provide the surgeon with tactile feedback when staple driver member (186) has been fully extended to staple the tissue, and subsequently when knife member (194) has been fully extended to cut the stapled tissue.

Once surgical stapler (10) has been fully fired, the surgeon releases firing trigger (38), which enables knife bar (70) and knife member (194) to automatically retract proximally relative to closure bar (50) via the resilient bias of knife return spring (130), described above. In the present version, knife bar (70) is operatively coupled with staple bar (60) such that proximal retraction of knife bar (70) relative to closure bar (50) also drives proximal retraction of staple bar (60) relative to closure bar (50); for example, via engagement of a lower tab (78) formed on a distal portion of knife bar (70) with a lower slot (66) formed in the underside of a distal portion of staple bar (60). Meanwhile, stapling detent features (185, 189) described above operate to maintain staple driver member (186) in its fully extended position within cartridge housing (162), such that distal lockout lever (270) disengages staple driver member (186). This allows distal lockout lever (270) to return to a raised lockout position and block re-actuation of firing trigger (38) now that staple cartridge unit (160) is spent. In this manner, distal lockout lever (270) prevents a surgeon from inadvertently re-firing spent staple cartridge unit (160) into tissue in a manner that would sever the tissue with knife (198) without applying staples.

Following release of firing trigger (38), the surgeon then depresses release button (110) on handle assembly (12) to permit closure trigger (36) and closure bar (50) to return to their unactuated states via the resilient bias of closure return spring (98), described above. Such proximal retraction of closure bar (50) draws cartridge housing (162) proximally away from anvil (210) so that the stapled and cut tissue may be released from end effector (16). Proximal retraction of closure bar (50) also draws staple bar (60) and knife bar (70) further proximally to their proximal home positions so that spent staple cartridge unit (160) may be removed from distal support structure (48) and replaced with a new staple cartridge unit (160).

II. Exemplary Alternative Tissue Cutting Washers

In some instances, it may be desirable to provide tissue cutting washer (240) of staple cartridge unit (160) with additional or alternative features to achieve other benefits during a surgical stapling procedure. Each of the exemplary alternative tissue cutting washers (300, 310, 320, 330, 360, 370, 380, 400) described below is suitable for use with staple cartridge unit (160) and surgical stapler (10) in place of tissue cutting washer (240) described above, and is configured to cooperate with knife (198) to cut tissue. It will be understood that each tissue cutting washer (300, 310, 320, 330, 360, 370, 380, 400) is similar to tissue cutting washer (240) described above except as otherwise described below, and that any one or more of the features of tissue cutting washers (300, 310, 320, 330, 360, 370, 380, 400) may be combined with one another and/or with the features of tissue cutting washer (240).

A. Exemplary Tissue Cutting Washers Having Alternative Side Flanges

FIG. 13 shows another exemplary tissue cutting washer (300) having a pair of side flanges (302) configured to cover an axial gap between distal hooks (47) of side plates (40) and plate portion (212) of anvil (210). Each side flange (302) varies in shape along a length of anvil plate portion (212). In particular, each side flange (302) includes a lower flange portion (304) having a first axial dimension, and a differently shaped upper flange portion (306) having a second, greater axial dimension. Such a configuration may optimize distribution of loads exerted on tissue cutting washer (300) during a firing operation.

FIG. 14 shows another exemplary tissue cutting washer (310) having a pair of side flanges (312) configured to cover an axial gap between distal hooks (47) of side plates (40) and plate portion (212) of anvil (210). Each side flange (312) includes a lower extension (314) that curves around a right-angle junction defined by the respective distal hook (47) and extends proximally toward cartridge housing (162) along a distal end of anvil coupling arm (214). Such a configuration provides enhanced coverage of an axial gap formed between distal hooks (47) and anvil plate portion (212) at a lower end of anvil plate portion (212), thereby further mitigating the risk of inadvertently pinching tissue within the axial gap during closure of end effector (16).

FIG. 15 shows another exemplary tissue cutting washer (320) having a pair of side flanges (322) configured to cover an axial gap between distal hooks (47) of side plates (40) and plate portion (212) of anvil (210). Side flanges (322) are similar to side flanges (312) of tissue cutting washer (310) in that each side flange (322) includes a lower extension (324) that curves around a right-angle junction defined by the respective distal hook (47). However, side flanges (322) are configured to extend proximally toward cartridge housing (162) along a majority of anvil coupling arm (214). Accordingly, side flanges (322) additionally protect against inadvertent pinching of tissue in transverse gaps between anvil coupling arm (214) and a corresponding axially extending lower section of distal jaw portion (46) of distal support structure (48).

B. Exemplary Tissue Cutting Washers Having Alternative Tissue Cutting Protrusions

While elongate cutting element (244) of tissue cutting washer (240) described above has a planar cutting surface, in other instances it may be desirable to configure cutting element (244) with other features. FIG. 16 shows an exemplary alternative tissue cutting washer (330) that is similar to tissue cutting washer (240) in that cutting washer (330) includes an elongate washer body (332), an elongate cutting element (334) that projects proximally from body (332) and protrudes through an elongate slot (352) of an anvil (350), and a pair of side flanges (336) that extend along lateral sides of anvil (350). A cutting surface of cutting element (334) includes a plurality of angled teeth (338) spaced along the length of cutting element (334), such that angled teeth (388) are positioned on the longitudinal centerline of cutting element (334). Angled teeth (338) may provide enhanced gripping and control of tissue while being stapled and cut, thus enhancing the precision of the applied staple rows and cut line.

FIG. 17 shows another exemplary tissue cutting washer (360) in combination with anvil (350). Tissue cutting washer (360) includes an elongate washer body (362) and an elongate cutting element (364) projecting proximally from washer body (362) and through anvil slot (352). Cutting element (364) includes a plurality of elongate cleats (366) arranged in side-by-side pairs spaced along a length of cutting element (364), such that each pair of cleats (366) straddles the longitudinal centerline of cutting element (364). Similar to angled teeth (338) of tissue cutting washer (330), elongate cleats (366) are configured to provide enhanced gripping and control of tissue while being stapled and cut.

FIG. 18 shows another exemplary tissue cutting washer (370) in combination with anvil (350). Tissue cutting washer (370) includes an elongate washer body (not shown) and an elongate cutting element (374) projecting proximally from the washer body and through anvil slot (352). Cutting element (374) includes a plurality of perforations (376) spaced along the length of cutting element (374), such that each perforation (376) extends laterally across the longitudinal centerline of cutting element (374). The provision of perforations (376) decreases the amount of material into which knife cutting edge (200) penetrates when cutting tissue, and thus may decrease a firing force required to be exerted by a surgeon on firing system (24) to fully fire surgical stapler (10).

FIG. 19 shows yet another exemplary tissue cutting washer (380) in combination with anvil (350). Tissue cutting washer (380) includes an elongate washer body (382) and an elongate cutting element (384) projecting proximally from washer body (382) and through anvil slot (352). Cutting element (384) includes a pair of raised textured strips (386) extending along a full length of cutting element (384), such that textured strips (386) straddle the longitudinal centerline of cutting element (384). Similar to angled teeth (338) and elongate cleats (366) described above, textured strips (386) are configured to provide enhanced gripping and control of tissue while being stapled and cut.

FIG. 20 shows an exemplary alternative cartridge housing (390) suitable for use with tissue cartridge unit (160) described above. Cartridge housing (390) is similar to cartridge housing (162) of staple cartridge unit (160) described above, except as otherwise described below. Cartridge housing (390) includes a deck (392) having an elongate knife slot (394) extending along a longitudinal centerline of deck (392), and a plurality of staple openings (396) positioned on either side of knife slot (394). Deck (392) of cartridge housing (390) further includes a pair of raised textured strips (398) positioned on either side of knife slot (394), inwardly of staple openings (396). Similar to textured strips (386) of tissue cutting washer (380) described above, textured strips (386) are configured to provide enhanced gripping and control of tissue while being stapled and cut.

C. Exemplary Tissue Cutting Washer With Detent Feature

In some instances, it may be desirable to provide staple cartridge unit (160) with additional features that maintain gap (G) between cartridge deck (164) and anvil plate portion (212) following removal of staple retainer (260) from cartridge unit (160) and prior to loading into distal support structure (48) of end effector (16). FIGS. 21A-21B show a modified version of staple cartridge unit (160) that includes an exemplary alternative tissue cutting washer (400) having a washer body (402) and an elongated proximal coupling arm (404) extending proximally from washer body (402). Elongated proximal coupling arm (404) includes a detent protrusion (406) arranged at a proximal end thereof, and which projects through an opening formed in proximal coupling arm (214) of anvil (210). Detent protrusion (406) of the present example is formed integrally with proximal coupling arm (404) and has a resilient construction. In other examples, detent protrusion (406) may be formed as a separate element that is supported by and operatively coupled with proximal coupling arm (404). In some such versions, detent protrusion (406) may be in the form of a domed head of press-fit pin (250) or an actuatable ball detent, for example.

As shown in FIG. 21A, a confronting side of cartridge housing (162) includes a corresponding detent recess (408) configured to releasably receive detent protrusion (406) with a detent engagement when end effector (16) is in the open state. Such detent engagement assists in maintaining a predetermined axial distance of cartridge gap (G), between anvil plate portion (212) and cartridge deck (164), in the absence of staple retainer (260), for example when staple retainer (260) has been removed prior to loading staple cartridge unit (160) into distal support structure (48). As shown in FIG. 21B, closure of end effector (16) via actuation of closure trigger (36) overcomes the detent engagement between detent protrusion (406) and detent recess (408), thus permitting cartridge housing (162) to advance distally to the closed position for clamping tissue.

III. Exemplary Combinations

The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to restrict the coverage of any claims that may be presented at any time in this application or in subsequent filings of this application. No disclaimer is intended. The following examples are being provided for nothing more than merely illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in numerous other ways. It is also contemplated that some variations may omit certain features referred to in the below examples. Therefore, none of the aspects or features referred to below should be deemed critical unless otherwise explicitly indicated as such at a later date by the inventors or by a successor in interest to the inventors. If any claims are presented in this application or in subsequent filings related to this application that include additional features beyond those referred to below, those additional features shall not be presumed to have been added for any reason relating to patentability.

Example 1

A staple cartridge unit configured for use with a surgical stapler, comprising: (a) a cartridge housing, wherein the cartridge housing includes: (i) a deck, and (ii) a plurality of openings formed in the deck, wherein the openings are configured to house a plurality of staples configured to be driven distally from the openings and into tissue positioned against the deck; (b) a knife movably disposed within the cartridge housing, wherein the knife is configured to be driven distally from the cartridge housing and through the tissue positioned against the deck; (c) an anvil arranged distal to the cartridge housing, wherein the anvil includes: (i) an elongate slot, and (ii) a plurality of staple-forming pockets disposed along the elongate slot; and (d) a cutting washer fixed relative to the anvil, wherein the cutting washer includes: (i) a cutting portion disposed within the elongate slot of the anvil, wherein the knife is movable distally to cut tissue against the cutting portion, and (ii) a pair of side flanges, wherein the side flanges extend transversely to the anvil and are configured to cover a gap defined between the anvil and a distal support structure of the surgical stapler in which the staple cartridge unit is received.

Example 2

The staple cartridge unit of Example 1, wherein the side flanges of the cutting washer extend along a full length of the anvil.

Example 3

The staple cartridge unit of any of the preceding Examples, wherein the cutting washer is disposed along a distal side of the anvil.

Example 4

The staple cartridge unit of any of the preceding Examples, wherein the anvil comprises a plate portion in which the staple-forming pockets are disposed, wherein the side flanges of the cutting washer extend along first and second opposed side edges of the plate portion.

Example 5

The staple cartridge unit of any of the preceding Examples, wherein the side flanges of the cutting washer are configured to prevent tissue from advancing inwardly into the gap defined between the anvil and the distal support structure of the surgical stapler.

Example 6

The staple cartridge unit of any of the preceding Examples, wherein the cutting portion of the cutting washer comprises an elongate protrusion, wherein the elongate protrusion projects proximally through the elongate slot of the anvil.

Example 7

The staple cartridge unit of any of the preceding Examples, wherein the cartridge housing is translatable relative to the anvil and the cutting washer along a translation axis between a proximal position and a distal position, wherein the deck extends transversely to the translation axis.

Example 8

The staple cartridge unit of Example 7, wherein the cartridge housing includes a first detent feature, wherein a proximally extending portion of the cutting washer provides a second detent feature, wherein the first and second detent features are configured to cooperate to releasably retain the cartridge housing in the proximal position.

Example 9

The staple cartridge unit of any of the preceding Examples, further comprising a guide pin that extends longitudinally between the cartridge housing and the anvil, wherein the cartridge housing is translatable along the guide pin.

Example 10

The staple cartridge unit of any of the preceding Examples, further comprising a tissue retaining pin, wherein the tissue retaining pin is selectively actuatable relative to the cartridge housing between a retracted position in which a distal tip of the tissue retaining pin is spaced proximally from the anvil, and an extended position in which the distal tip engages the anvil to thereby retain tissue between the anvil and the cartridge housing.

Example 11

The staple cartridge unit of any of the preceding Examples, further comprising a staple driver member movably disposed within the cartridge housing, wherein the staple driver member is operable to drive the staples distally from the openings.

Example 12

The staple cartridge unit of Example 11, wherein the staple driver member is actuatable relative to the cartridge housing independently of the knife.

Example 13

The staple cartridge unit of any of the preceding Examples, wherein the openings in the deck of the cartridge housing are arranged in a plurality of linear rows, wherein the knife includes a linear cutting edge.

Example 14

A surgical stapler comprising: (a) a body assembly; (b) a shaft assembly extending distally from the body assembly; and (c) an end effector at a distal end of the shaft assembly, wherein the end effector comprises: (i) a support structure, and (ii) the staple cartridge unit of claim 1, wherein the staple cartridge unit is removably received by the support structure such that the deck of the cartridge housing extends transversely to a longitudinal axis of the shaft assembly.

Example 15

The surgical stapler of Example 14, wherein each of the side flanges of the cutting washer extends proximally over a respective side of the anvil and distally over a respective side of a distal portion of the support structure.

Example 16

A staple cartridge unit configured for use with a surgical stapler, comprising: (a) a cartridge housing, wherein the cartridge housing includes: (i) a deck, (ii) a plurality of openings formed in the deck, wherein the openings are configured to house a plurality of staples configured to be driven distally from the openings and into tissue positioned against the deck, and (iii) a first detent feature; (b) a knife movably disposed within the cartridge housing, wherein the knife is configured to be driven distally from the cartridge housing and through the tissue positioned against the deck; (c) an anvil arranged distal to the cartridge housing, wherein the anvil includes: (i) an elongate slot, and (ii) a plurality of staple-forming pockets disposed along the elongate slot; (d) a cutting washer fixed relative to the anvil, wherein the cutting washer includes a cutting portion disposed within the elongate slot of the anvil, wherein the knife is movable distally to cut tissue against the cutting portion; and (e) a second detent feature supported by the cutting washer, wherein the cartridge housing is selectively actuatable relative to the anvil between a proximal position in which the deck is spaced proximally from the anvil, and a distal position in which the deck is configured to clamp tissue against the anvil, wherein the first and second detent features are configured to cooperate to releasably retain the cartridge housing in the proximal position.

Example 17

The staple cartridge unit of Example 16, wherein the cutting washer further includes an arm that extends proximally relative to the cutting portion, wherein the arm provides the second detent feature.

Example 18

The staple cartridge unit of any of Examples 16 through 17, wherein the first detent feature comprises a recess, wherein the second detent feature comprises a projection configured to releasably engage the recess.

Example 19

A surgical stapler comprising: (a) a body; (b) a shaft assembly extending distally from the body along a shaft axis; and (c) an end effector at a distal end of the shaft assembly, wherein the end effector comprises: (i) a support structure, and (ii) a staple cartridge unit removably received by the support structure, wherein the staple cartridge unit comprises: (A) a cartridge housing coupled with a proximal portion of the support structure, wherein the cartridge housing includes a deck that extends transversely to the shaft axis, wherein the deck includes a plurality of openings configured to house a respective plurality of staples, (B) a knife movably disposed within the cartridge housing, (C) an anvil plate fixed relative to a distal portion of the support structure, wherein the anvil includes an elongate slot and a plurality of staple-forming pockets disposed along the elongate slot, and (D) a cutting washer fixed relative to the anvil plate, wherein the cutting washer includes a cutting portion against which the knife is configured to cut tissue, wherein the cutting washer further includes a pair of side flanges operable to prevent tissue from entering between the anvil plate and the distal portion of the support structure.

Example 20

The surgical stapler of Example 19, wherein each of the side flanges extends proximally over a respective side of the anvil plate and distally over a respective side of the distal portion of the support structure.

IV. Miscellaneous

It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The above-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

Further, any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the teachings, expressions, embodiments, examples, etc. described in U.S. Pat. App. No. [Atty. Ref. END9087USNP1], entitled “Clamping Based Lockout Mechanism for Right Angle Surgical Stapler,” filed on even date herewith; U.S. Pat. App. No. [Atty. Ref. END9088USNP1], entitled “Cartridge Based Lockout Mechanism for Right Angle Surgical Stapler,” filed on even date herewith; and U.S. Pat. App. No. [Atty. Ref END9090USNP1], entitled “Staple Retainer for Right Angle Surgical Stapler,” filed on even date herewith, the disclosures of which are incorporated by reference above.

It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

Versions of the devices described above may have application in conventional medical treatments and procedures conducted by a medical professional, as well as application in robotic-assisted medical treatments and procedures. By way of example only, various teachings herein may be readily incorporated into a robotic surgical system such as the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif. Similarly, those of ordinary skill in the art will recognize that various teachings herein may be readily combined with various teachings of any of the following: U.S. Pat. No. 5,792,135, entitled “Articulated Surgical Instrument For Performing Minimally Invasive Surgery With Enhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, the disclosure of which is incorporated by reference herein; U.S. Pat. No. 8,783,541, entitled “Robotically-Controlled Surgical End Effector System,” issued Jul. 22, 2014, the disclosure of which is incorporated by reference herein; U.S. Pat. No. 8,479,969, entitled “Drive Interface for Operably Coupling a Manipulatable Surgical Tool to a Robot,” issued Jul. 9, 2013; U.S. Pat. No. 8,800,838, entitled “Robotically-Controlled Cable-Based Surgical End Effectors,” issued Aug. 12, 2014, the disclosure of which is incorporated by reference herein; and/or U.S. Pat. No. 8,573,465, entitled “Robotically-Controlled Surgical End Effector System with Rotary Actuated Closure Systems,” issued Nov. 5, 2013, the disclosure of which is incorporated by reference herein.

Versions of the devices described above may be designed to be disposed of after a single use, or they can be designed to be used multiple times. Versions may, in either or both cases, be reconditioned for reuse after at least one use. Reconditioning may include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces, and subsequent reassembly. In particular, some versions of the device may be disassembled, and any number of the particular pieces or parts of the device may be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular parts, some versions of the device may be reassembled for subsequent use either at a reconditioning facility, or by a user immediately prior to a procedure. Those skilled in the art will appreciate that reconditioning of a device may utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

By way of example only, versions described herein may be sterilized before and/or after a procedure. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or high-energy electrons. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile container for later use. A device may also be sterilized using any other technique known in the art, including but not limited to beta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometries, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings. 

I/we claim:
 1. A staple cartridge unit configured for use with a surgical stapler, comprising: (a) a cartridge housing, wherein the cartridge housing includes: (i) a deck, and (ii) a plurality of openings formed in the deck, wherein the openings are configured to house a plurality of staples configured to be driven distally from the openings and into tissue positioned against the deck; (b) a knife movably disposed within the cartridge housing, wherein the knife is configured to be driven distally from the cartridge housing and through the tissue positioned against the deck; (c) an anvil arranged distal to the cartridge housing, wherein the anvil includes: (i) an elongate slot, and (ii) a plurality of staple-forming pockets disposed along the elongate slot; and (d) a cutting washer fixed relative to the anvil, wherein the cutting washer includes: (i) a cutting portion disposed within the elongate slot of the anvil, wherein the knife is movable distally to cut tissue against the cutting portion, and (ii) a pair of side flanges, wherein the side flanges extend transversely to the anvil and are configured to cover a gap defined between the anvil and a distal support structure of the surgical stapler in which the staple cartridge unit is received.
 2. The staple cartridge unit of claim 1, wherein the side flanges of the cutting washer extend along a full length of the anvil.
 3. The staple cartridge unit of claim 1, wherein the cutting washer is disposed along a distal side of the anvil.
 4. The staple cartridge unit of claim 1, wherein the anvil comprises a plate portion in which the staple-forming pockets are disposed, wherein the side flanges of the cutting washer extend along first and second opposed side edges of the plate portion.
 5. The staple cartridge unit of claim 1, wherein the side flanges of the cutting washer are configured to prevent tissue from advancing inwardly into the gap defined between the anvil and the distal support structure of the surgical stapler.
 6. The staple cartridge unit of claim 1, wherein the cutting portion of the cutting washer comprises an elongate protrusion, wherein the elongate protrusion projects proximally through the elongate slot of the anvil.
 7. The staple cartridge unit of claim 1, wherein the cartridge housing is translatable relative to the anvil and the cutting washer along a translation axis between a proximal position and a distal position, wherein the deck extends transversely to the translation axis.
 8. The staple cartridge unit of claim 7, wherein the cartridge housing includes a first detent feature, wherein a proximally extending portion of the cutting washer provides a second detent feature, wherein the first and second detent features are configured to cooperate to releasably retain the cartridge housing in the proximal position.
 9. The staple cartridge unit of claim 7, further comprising a guide pin that extends longitudinally between the cartridge housing and the anvil, wherein the cartridge housing is translatable along the guide pin.
 10. The staple cartridge unit of claim 9, further comprising a tissue retaining pin, wherein the tissue retaining pin is selectively actuatable relative to the cartridge housing between a retracted position in which a distal tip of the tissue retaining pin is spaced proximally from the anvil, and an extended position in which the distal tip engages the anvil to thereby retain tissue between the anvil and the cartridge housing.
 11. The staple cartridge unit of claim 1, further comprising a staple driver member movably disposed within the cartridge housing, wherein the staple driver member is operable to drive the staples distally from the openings.
 12. The staple cartridge unit of claim 11, wherein the staple driver member is actuatable relative to the cartridge housing independently of the knife.
 13. The staple cartridge unit of claim 1, wherein the openings in the deck of the cartridge housing are arranged in a plurality of linear rows, wherein the knife includes a linear cutting edge.
 14. A surgical stapler comprising: (a) a body assembly; (b) a shaft assembly extending distally from the body assembly; and (c) an end effector at a distal end of the shaft assembly, wherein the end effector comprises: (i) a support structure, and (ii) the staple cartridge unit of claim 1, wherein the staple cartridge unit is removably received by the support structure such that the deck of the cartridge housing extends transversely to a longitudinal axis of the shaft assembly.
 15. The surgical stapler of claim 14, wherein each of the side flanges of the cutting washer extends proximally over a respective side of the anvil and distally over a respective side of a distal portion of the support structure.
 16. A staple cartridge unit configured for use with a surgical stapler, comprising: (a) a cartridge housing, wherein the cartridge housing includes: (i) a deck, (ii) a plurality of openings formed in the deck, wherein the openings are configured to house a plurality of staples configured to be driven distally from the openings and into tissue positioned against the deck, and (iii) a first detent feature; (b) a knife movably disposed within the cartridge housing, wherein the knife is configured to be driven distally from the cartridge housing and through the tissue positioned against the deck; (c) an anvil arranged distal to the cartridge housing, wherein the anvil includes: (i) an elongate slot, and (ii) a plurality of staple-forming pockets disposed along the elongate slot; (d) a cutting washer fixed relative to the anvil, wherein the cutting washer includes a cutting portion disposed within the elongate slot of the anvil, wherein the knife is movable distally to cut tissue against the cutting portion; and (e) a second detent feature supported by the cutting washer, wherein the cartridge housing is selectively actuatable relative to the anvil between a proximal position in which the deck is spaced proximally from the anvil, and a distal position in which the deck is configured to clamp tissue against the anvil, wherein the first and second detent features are configured to cooperate to releasably retain the cartridge housing in the proximal position.
 17. The staple cartridge unit of claim 16, wherein the cutting washer further includes an arm that extends proximally relative to the cutting portion, wherein the arm provides the second detent feature.
 18. The staple cartridge unit of claim 16, wherein the first detent feature comprises a recess, wherein the second detent feature comprises a projection configured to releasably engage the recess.
 19. A surgical stapler comprising: (a) a body; (b) a shaft assembly extending distally from the body along a shaft axis; and (c) an end effector at a distal end of the shaft assembly, wherein the end effector comprises: (i) a support structure, and (ii) a staple cartridge unit removably received by the support structure, wherein the staple cartridge unit comprises: (A) a cartridge housing coupled with a proximal portion of the support structure, wherein the cartridge housing includes a deck that extends transversely to the shaft axis, wherein the deck includes a plurality of openings configured to house a respective plurality of staples, (B) a knife movably disposed within the cartridge housing, (C) an anvil plate fixed relative to a distal portion of the support structure, wherein the anvil includes an elongate slot and a plurality of staple-forming pockets disposed along the elongate slot, and (D) a cutting washer fixed relative to the anvil plate, wherein the cutting washer includes a cutting portion against which the knife is configured to cut tissue, wherein the cutting washer further includes a pair of side flanges operable to prevent tissue from entering between the anvil plate and the distal portion of the support structure.
 20. The surgical stapler of claim 19, wherein each of the side flanges extends proximally over a respective side of the anvil plate and distally over a respective side of the distal portion of the support structure. 